Preparation of latices



Oct. 4, 1966 w. M. HALPER ETAL 3,277,037

PREPARATION OF LATICES Filed Sept 19, 1962 INVE NTORSI R E PS LS MW N E MY A L R D l w A M WF United States Patent Oflfice 3,277,037 Patented Oct. 4, 1966 3,277,037 PREPARATION OF LATICES Walter M. Halper, San Pedro, and Fred Dudley Moss, Long Beach, Calitl, assignors to Shell Oil Company, New York, N.Y., a corporation of Delaware Filed Sept. 19, 1962, Ser. No. 224,648 2 Claims. (Cl. 26027) This invention relates to the process for producing latices of synthetic polymers. More particularly, it relates to improved processes for producing latices of polymers (elastomers) from organic solvent solutions thereof.

The art and technology relating to latices of synthetic polymers is highly developed. In the prior art, synthetic elastomers and other polymers are commonly prepared by emulsion polymerization techniques whereby the resulting product at the end of the polymerization is a suspension wherein the solids content varies depending upon the particular art and technology involved. Thus, for example, synthetic elastomers of the type represented by styrene-butadiene copolymers are suitably prepared by emulsion polymerization in the presence of water and emulsifying agents so that the resulting product is an aqueous suspension of the copolymer together with the unreacted monomers.

In such emulsion polymerization processes, the copolymer ultimately may be separated upon the addition of precipitants such as salt and acid, whereupon a crumb of the rubber is obtained which is easily separated from the aqueous phase. Synthetic latex, as distinguished from crumb, is highly useful in the production of foam rubber or cellular products. The latex usually is obtained from the emulsion by flashing to remove unreacted monomer and some water, the resulting product being latex.

In many instances, the preparation of latex from particular rubbers by these flashing procedures results in great difficulties relative to excessive foaming of the products involved especially if substantial amounts of solvents or monomers must be removed. The foam appears to be accentuated as the temperature is raised in an eflort to flash off hydrocarbon constituents, the solvent vapors being intimately mixed with evolving latex to such an extent that a froth or foam is formed which has been found to be diflicult in many cases to resolve and which clogs vapor recovery apparatus.

In recent years, synthetic elastomers produced by solution polymerization methods have received much attention mainly due to advances and changes in elastomer technology. The problems of emulsifying the cements so produced to make latices therefrom have created difliculties not heretofore experienced because material differences exist not only within the elastomers per se but also because the solutions of these elastomers have different rheological properties and characteristics from those of prior products.

The presence of large proportions of solvents and the requirement for relatively large proportions of emulsifying agents (compared with the requirements of an emulsion polymerization process) compound the foaming problem.

It would be highly desirable to devise a process for the conversion of synthetic polymer (elastomer) cements into latex form without encountering the difficulties briefly referred to herein'before. It would be especially desirable to devise a process which would minimize or eliminate the problems usually connected with undue foaming of the product and, more specifically to take advantage of the necessity for flashing off the solvent in such a manner as to cause stable foam formation.

A method has been devised which permits stripping elastomeric emulsions which form very stable foams by sending both vapor and emulsion together as foam into a condenser, collapsing foam and phase separating the solvent. It is remarkable that, despite sending the foam through the condenser, fouling is at a minimum. Poor stripping results from insuflicient time for solvent diffusion. Contacting cold surfaces before reaching the condenser could result in poor stripping.

One difliculty encountered in this process is based in part upon the poor heat conductivity of the foam due no doubt to the high percentage of the volume of vaporized solvent which is in the foam. This results in an unevenly constituted foam and, in turn, causes variable condensation results during the later foam collapsing stage. Time is normally lacking for heat transfer from water to solvent and for vaporized solvent to escape from the viscous cement. Therefore, the latex may contain substantial quantities of unstripped rubber cement. The present process according to this invention is designed to overcome these difliculties.

Now, in accordance with the present invention, a process for the production of a latex of a synthetic elastomer comprises mixing Water with a cement of the elastomer dissolved in an organic solvent having no more than a small solubility in water and an emulsifying agent, emulsifying the mixture so formed and heating the emulsion to create the foam described briefly hereinabove under such conditions that the rubber cement solvent vaporizes while most of the water remains in a liquid state. Under the balanced conditions employed, substantially all of the emulsion components are incorporated in a foam, but, due to the relatively rapid heating desired for efliciency purposes, the foam has unstripped solvent in the dispersed phase. The present invention provides for diffusion of the solvent from the cement prior to its collapse by holding it for a sufiicient time to cause the attainment of equilibrium between unstripped solvent and its dispersed phase polymer counterpart. Thereafter, the foam is subjected to collapsing treatment, such as cooling or increase in pressure, for the purpose of reducing the vaporized solvent to a liquid state.

In the course of the vaporization and subsequent condensation of the cement solvent, the rubber is converted into colloidally dispersed rubber particles which are suspended in the water containing an emulsifying agent, thus forming a latex. Subsequent to the condensation stage, phase separation is effected to remove the cement solvent phase and thus separate it from the latex phase. In the course of this separation, the cement solvent phase is recovered containing no more than a minor amount of the rubber originally present therein, while the latex is recovered containing no more than a minor proportion of the solvent originally present in the cement.

THE POLYMER The process of this invention is applied to any hydrocarbon polymer that is in the form of a cement before being emulsified. It is immaterial how the cement of the polymer is obtained. Preferably of course the polymer is a synthetic elastomer and still more proferably, a rubbery polymer (including copolymers) of conjugated dienes. The solvent utilized in forming the cement (polymer solution) preferably has a small but measurable solubility in water, e.g., 0.5-5 cc. per liter of water at 20 C. The preferred class of solvents comprises those boiling at least 40 C. below the boiling point of water under a given set of conditions, i.e., pressure, although the process can be adjusted to accomodate higher boiling solvents such as toluene. Still more particularly, the solvents considered most suitable for use in the latex forming process of this invention comprise hydrocarbons which are solvents for the rubbers employed and have boiling points below about 60 C. at atmospheric pressure.

of emulsions.

' gated dienes which are polymerized by solution polymerization utilizing the so-called low pressure -polymerization methods wherein the polymerization catalyst may be the reaction product of a halide of a transition metal within groups 48 of the periodic table and a reducing agent such as an aluminum alkyl, aluminum alkyl halide, aluminum halide and the like. Lithium alkyl-s, alone or in combination with lithium metal are also suitable polymerization catalysts for conjugated dienes. Thus, polybutadiene or polyisoprene having a cis 1,4-content as high as about 95% maybe obtained while by other methods polymers having a high trans .1,4-content may be prepared if so desired.

Another class of synthetic polymers comprise the copolymers prepared from ethylene and one or more monoolefins having up to 8 carbon atoms and ter-polyrners having a diene in a minor proportion. Suitable copolymers include especially the copolymers of ethylene and propylene which may be either elastomeric or plastic depending upon the relative proportions of ethylene and propylene and the copolymers of ethylene with butene-l and the like. Elastomeric ter-polymers prepared by solution polymerization are also equally suitable for the purposes of the present invention, such as the ter-polymer obtained by the combination of ethylene, propylene and a .diene such as 1,5-hexadiene, cyclopentadiene, dicyclopentadiene or cyoloh'eptadiene, prepared by polymerization of a mixture of monomers with a catalyst which may be the reaction product of a reducing agent of the kind indicated above and a vanadium compound such as vanadium halides, vanadium oxy halides, vanadium esters and the like. The usual solvents employed for these polymerizations and suitable for use in present processes include hydrocarbons having from 4 to 9 carbon atoms each and preferably from 4-5 carbon atoms each including butanes, pentanes, hexanes, butylenes, amylenes, benzenes, toluene, halogenated derivatives thereof and other relatively inactive diluents and solvents known in the art.

Persons skilled in the art will understand that these hydrocarbon elastomers comp-rise those that are of relatively recent origin. The elastomer solutions are characterized by being very high in viscosity even at low elastomeric polymer content. Thus, the solids content of the elastomer solution at the end of the polymerization rarely exceeds 30% by weight and in fact at such concentrations, great material handling problems are presented so that the solutions usually contain in the order of -20% by weight of the elastomer.

When the cement is emulsified, the solid content is preferably substantially less than if it is to be processed to form a crumb. The invention, however, is not critically limited to elastomers prepared by the low pressure processes and any hydrocarbon elastomers produced by solution processes may also be the subject of the present invention. Alternatively, elastomers that are in solid form or in latex suspension may be dissolved or redissolved after preparation by other means. When used within this specification, the term synthetic elastomer makes reference to synthetic elastomers defined according to ASTM special technical publication No. 184, page 138, wherein the elastomer is further characterized in being essentially completely soluble in any organic solvent.

THE EMULSIFICATION The emulsification of the polymer solution comprises bringing together water, an emulsifying agent and the polymer cement. The apparatus which has been ernployed for emulsification should be designed for the purpose of homogenizing such mixtures for the production In this regard, a centrifugal pump with a variable speed control and/or a bypass is found to be suitable although other homogenizing equipment may be used in place thereof.

It will be found that the maximum throughput rate in a given piece of apparatus may be substantially increased if the concentration of the polymer in the organic solvent is restricted so as to utilize an optimum viscosity which will vary depending upon the particular apparatus and the particular polymer employed. The viscosity is not only dependent upon the concentration of the polymer in its cement but also upon the average molecular weight of the polymer contained therein. Taking as an example, cis 1,4-polyisoprene solution in an aliphatic diluentsuch as isopentane or isoamylene, suitable throughput rates are experienced at concentrations in the order of 1020%, although much faster throughput rates may be experi enced if the concentration is maintained in the order of 7-10% by weight, the intrinsic viscosity of the polymer contained in the cement being between about 4 and 14 d1./ g.

The amount of emulsifying agents and of water emulsified together with the polymer cement depends on such factors as the particular synthetic elastomer being emulsified or upon the particular non-elastomeric polymer prescut. The proportion will also vary depending upon the emulsification apparatus, the identity of the emulsifying agent, the concentration of the elastomer solution and other variables including temperature. It should be emphasized that the proportion of emulsifying agent utilized at this point in the process is not necessarily the concentration of emulsifying agent which will remain in the latex eventually produced after the claimed process. Generally, the minimum amount of emulsifying agent needed for emulsification ranges from about 2 to 30 parts per of polymer (phr.), but the amount that is contained in the most preferred concentrated latex is usually lower that the 30 parts specified above and will vary depending upon the particular elastomeric latex that is being prepared. Amounts from about 1 to about 3 phr. usually are optimum.

Any of the emulsifying agents employed in the emulsion polymerization art may be suitably employed for the purposes of the present invention. Preferably, the emulsifying agents are soaps and particularly alkali metal soaps of monocar-boxylic acids. The sodium or potassium soaps of rosin acids are especially preferred although mixed soaps such as the soaps of tall oil acids, saturated or unsaturated fatty acids such as oleic, palmitic, stearic, lauric, myristfc, castor oil acids and similar acids may be employed in the preparation of suitable emulsifying soaps.

In addition to, or in place of, the soap emulsifying agents, other emulsifiers may be utilized including cationic or non-ionic water-dispersable emulsifiers particularly the amine salts of hydroxyl amines and long chain fatty acids esters as well as quaternary ammonium salts such as tridecyl benzene, hydroxy ethyl, imidazoline chloride and stearyl dimethyl benzenyl ammonium chloride and the like. Nonionic surfactants which may be utilized for this purpose are represented by phosphoric acid esters of higher alcohols such as capryl and octyl alcohols, monoesters of oleic acid with pentaerythritol, sorbitan monooleate and the like. I

The emulsifying agent is preferably added to the mixture being prepared for emulsification in the form of an aqueous solution or dispersion and desirably is in concentrations in the order of 0.52% based on the eventual aqueous phase of the emulsion. The amount of water contained in the total composition for emulsification will normally range from about 40 to about 300 parts per hundred parts by volume of elastomer solution (cement), with amounts in the order of 50-100 being preferable.

It will be readily appreciated that the emulsification procedures may be varied within the knowledge of the art. Thus, the emulsifying agent may be prepared in situ by adding the soap forming acid to the elastomer solution and adding an alkali metal hydroxide to the aqueous phase. The reaction of the alkali metal hydroxide and soap forming acid occurs during emulsification. If desired, all of the ingredients that are to be emulsified may be charged to a single vessel which is under constant agitation and the blend may be continuously fed to an emulsifying apparatus. Alternatively, water, solution of emulsifying agent and elastomer solution (cement) may be fed by separate inlets into the emulsifying apparatus in the desired proportions and the resulting aqueous emulsion recovered and stored for subsequent processing.

The proportion of emulsifying agent is adjusted for the purpose of forming a relatively stable emulsion under the conditions and time period required for latex formation and' moreover must be adjusted to the point where transfer of the rubber from its organic solvent solution into colloidal suspension in the aqueous phase may be easily accomplished. Emulsions that are not stable are characterized by two layers and will result in latices of uneven quality, with large globules of undispersed cement distributed more or less irregularly throughout the latex.

As previously indicated, the aqueous emulsion of the synthetic polymer should be sufficiently stable in order to produce a desirable latex. Emulsions which are not stable are characterized by at least partial separation of the emulsion into two layers. The stability of the emulsion depends largely upon the average particle size of the polymer phase and this size is most simply controlled by adjusting the concentration and type of the emulsifier in the aqueous phase in relation to the polymer-solvent phase. The particle size also may be decreased by reducing the throughput rate through the emulsification apparatus and/or increasing the degree of external recycle around the homogenizing apparatus. These measures may be undertaken alone or in combinations of varying the amount of emulsifying agent and the concentration of the polymer solution. The resulting product from the emulsification step should contain in the order of 3-15 by weight of solid depending on the amount of water used, the amount in the order of 5-10% being preferred for reasons of overall efiiciency, economy and optimum technical properties.

FOAMING OPERATION The emulsion so formed is then in condition for the preparation of foam in accordance with the present invention. The foaming operation is accomplished by one of two alternatives or combinations thereof. The solvent -for the polymer (hereinafter referred to as the rubber) is one having a solubility in water of no more than about 5 cc. per liter of water at 20 C. The rubber solvent may have any boiling point suitable for vaporization of the solvent below rubber degradation temperature, preferably below 150" C. Preferably, it has a boiling point (or boiling points if a mixture), lower than that of the boiling point of water under the same pressure conditions. In order for the foaming operation to be accomplished with an optimum degree, it is preferred that the solvents have a boiling point lower than about 40 C. below that of water. The reason for this will become apparent during the description of the foaming operation.

Foaming is accomplished by either heating the emulsion sufiiciently to vaporize at least a substantial proportion of the rubber solvent without vaporizing more than a minor proportion of water or, on the other hand, the foaming may be accomplished by pre-heating and reducing pressure until the same type of foaming is accomplished. It is to be emphasized that the foaming operation is carried out with the end result of vaporizing the rubber solvent without causing any substantial massive escape of the solvent from the foam. In other words, the foaming operation is not considered to be a fractional distillation or flashing in any sense. It is on the contrary, the creation of gaseous bubbles throughout the heated or depressurized emulsion suflicient to cause the formation of a foam resembling shaving cream or froth, thus constituting extremely intimate mixtures of vaporized solvents dispersed throughout the liquid phase, the liquid phase comprising the aqueous dispersion of colloidal rubber particles and a colloidal solution of the emulsifying agent.

The particular piece of apparatus utilized for accomplishing this step is not critical. This is best accomplished by employing a heat exchanger tube bundle wherein the emulsion passes either inside or outside the tubes surrounded by a heat exchange medium of any desired description, or by employing direct steam addition to the emulsion in a suitable vessel. W

It is at this point that the desirability of the present invention becomes apparent. The means of rapid heating, preferably by heat transfer equipment tubes of short length and with minimum agitation therein results in too short a time lapse for diffusion of the vaporized solvent to the interface of the cement particles. This disadvantageous aspect results in more uneven distribution of solvent than if time were allowed for proper equilibrium to be established between the phases.

Under many circumstances this would not be of any technical importance; however, in the present case, where the equilibrium of the foam components largely affects their eventual physical form and ease of separation, the present invention comprises the provision of sufiicient time for equilibrium to be established. The time necessary cannot be stated with precision, since it will depend on all of the process conditions, such as solvent, rubber viscosity and concentration, temperature and cement particle size. If an undue amount of solvent is retained in the rubber, the colloidal particles thereof are highly swollen and form a slime, as referred to hereinafter. This, in turn, complicates recovery problems and not only requires special handling to cause proper separation from the main body of the condensed solvent but also requires extensive subsequent steps for the elimination of the solvent trapped in the rubber particles.

It is preferred that this solvent diffusion be effected in a minimal length of time, preferably between about 0.1 and 2.5 minutes, preferably 0.25-1.25 minutes, the time being determined by the rate of diffusion of the solvent and by the nature of the polymer and particle size of the emulsion. The equilibrium step is preferably carried out in a vessel comprised of a time tank or the foam may be moved through a pipe arrangement under conditions that permit equilibration throughout the foam body.

FOAM COLLAPSE Having created the foam for the purpose of separating the rubber solvent from colloidal rubber particles, the next stage in the process comprises collapsing the foam prior to separation of the phases. This may be accomplished either by increasing the pressure on the system sufliciently to liquify the solvent vapors or by cooling the foam to an extent sufficient to obtain this same result. Of course, combinations of these two alternatives may be utilized. As intimated, hereinbefore, foam collapse is preferably accomplished with a minimum of agitation preferably by passage through a heat exchange bundle designed particularly for this purpose in having a relatively large number of tubes with relatively short lengths. Minimum turbulence is achieved when the foam passes through the shell of the exchanger, the cooling medium being sent through the tubes. Cooling or pressure are designed to be sufficient for reducing the vaporized solvent to a liquid state but insufficient to solidify either the solvent or the aqueous phase. In other words, the foam collapse is accomplished under such conditions that the major phases comprise liquid solvent, liquid water, and colloidal dispersions of emulsifying agents and of rubber particles. The purpose of mini- 7 mum agitation during. foam collapse is to minimize reincorporation of separated rubber solvent into the aqueous phase.

SOLVENT REMOVAL The collapsed foam mixture comprises a relatively intimate admixture of the two immiscible phases, namely, organic solvent and aqueous latex. Due to unavoidable agitation, there is usually an unresolved phase comprising admixture of rubber, residual solvent and soap con- .taining emulsifier, droplets of such complicated mixtures being intimately dispersed in a portion of the liquidified solvent phase. This resembles a slime and is often difficult to resolve. It has been found, however, that resolutions are readily accomplished if the entire collapsed foam mixture is passed through a coalescer packed with a fibrous material such as steel wool, steel filings, York matting, glass wool or the like. Coalescence for the resolution of any slime phase may be accomplished at this point or after the solvent removal step now to be described.

The mixture is then sent to a settler or decanter wherein the liquidified solvent forms a separate phase from the aqueous latex. It is then a simple matter to decant or otherwise remove the solvent phase from the latex phase. The interface between these two phases will contain any slime as described above if coalescence has not been performed or has been incomplete. Thus, coalescence can take place there prior to decanting as described above or may be accomplished by passing the separated solvent phase together with slime through the same type of coalescer. Of course, the passage through a coalescer may be accomplished at both points if de sired and if operation is found to be more efficient by this means.

RESIDUAL SOLVENT REMOVAL The latex recovered from the solvent separation step normally comprises a major proportion of water containing substantial amounts of emulsifying agent and a colloidally dispersed minor proportion of the hydrocarbon polymer (rubber). Furthermore, there usually will be present a minor residual amount of the solvent which was not removed from the system by the steps previously described. While it is highly desirable to remove this residual solvent, it may at this particular point serve a useful purpose in the optional concentration of the latex. Since the specific gravity of the organic solvents are almost always substantially less than that of water, and therefore, the combination of rubber with residual solvent constitutes a phase of lower specific gravity than that of Water, it is possible to efliciently centrifuge the latex to remove a substantial portion of the aqueous soap phase and recover a concentrated latex. This is desirable with respect to the efiiciency of the steps to be described hereinafter since a large proportion of the aqueous emulsifier phase must or should be removed at some later stage in i the latex forming process and moreover may improve the efficiency of residual solvent removal now to be accomplished.

While residual solvent may be removed by flashing techniques, it is preferable to repeat foam formation and foam collapse followed by decanting of the resulting separate phases. The conditions for foam removal and collapse are substantially those described hereinbefore for the initial utilization of these two processing steps. Likewise, the coalescence and removal aspects (decanting) are essentially those previously described.

LATEX CONCENTRATION The latex derived as described above now comprises an excessively large aqueous emulsifier phase having polymer particles colloidally dispersed therein either with or without minor residual portions of solvent. A second decanting step may be accomplished after heating the latex sufficiently to promote further phase separation of any residual solvent although this step is not essential. The latex can be concentrated by passing it through a centrifuge whereby a major proportion of the aqueous emulsifier phase is removed and separated from a concentrated latex phase which now may contain upwards of by weight of colloidally dispersed hydrocarbon polymer (rubber) together with the remaining portion of the aqueous emulsifier phase. The conditions of centrifuging are controlled to accomplish the degree of separation desired and will depend in part upon the precise concentration of the several components referred to here as well as the toleration of the emulsification agent in the final latex end use. Still further solvent removal may be accomplished by passing the concentrated latex through flashing drums or strippers and optionally the latex may be subjected to a second or further centrifuging operation or operations to remove still further portions of the aqueous emulsifier phase referred to as serum.

CONCENTRATED LATEX The solids content of the latex is of considerable im-' portance when the latex is to be used for the preparation of dipped goods and vulcanized foam. When the latex is to be employed as an intermediate for the recovery of rubber by coagulation, the solids content and content of emulsifying agent are of decreasing importance. The required solids content of the concentrated latex will vary depending on such factors as the elastomer species, the species of the emulsifying agents and the ultimate utility. Generally, the solids content of the latex should be in excess of 50% by weight, preferably -75% by weight being specifically determined in each case. For cis l,4-polyisoprene latex, it is most preferred that the solids content be in excess of about and generally between and for cis 1,4-polybutadiene the solids content may be considerably less and still be acceptable, but in no case should the solids content be below about 50% by weight, when the latex is to be used for the preparation of vulcanized foams or dipped goods.

The process of the invention will be described with particular reference to the figure. A cis 1,4-polyisoprene cement containing 10% by 'weight of polyisoprene, the solvent being mixed amylenes, is taken from a source 1 through line 2 to a blend and surge tank 3 wherein it is mixed with an approximately equal amount of water containing 1.5% by weight (basis water) of potassium rosinate, from a source 4 via line 5. The mixture from the blend tank 3 is then passed by means of line 6 and eductor 7 to an emulsification device 8 which is operated at an exit temperature of about .F. The emulsion is recycled by means of lines 9 and 10 to ensure maximum dispersal in the emulsification device. Preferably, the emulsified mixture is then passed to the holding tank 11 wherein a recycle of about 15% of the emulsified material is passed back into line 10. This proportion being recycled so as to insure complete emulsification of any minor amount of the emulsification mixture not previously fully emulsified.

The finished emulsion is then passed by means of line 12 to the heat exchange bundle 13 comprising the foam forming unit which is operated at about 200 F. under 15 p.s.i.g. In this unit, the material which exits comprises a foam of shaving cream consistency which is passed to the time tank 14 for a residence period of less than about 1 minute in order to enable the solvent to reach its equilibrium concentration relative to the polymer throughout the foam. The product then proceeds to the foam condenser 15 wherein the foam is chilled to about 110 F. at 10 p.s.i.g. thus causing a collapse of the foam due to condensation of the vaporized solvent to a liquid state. The condensed foam passes by means of line 16 through coalescer 17 which is packed with steel wool for the purpose of further resolving the separate phases of solvent and latex.

The coalesced and condensed material then passes by means of line 18 to a decanter 19 wherein it is stored for a sufficient time at about 110 F. and p.s.i.g. to cause a substantial settling of the phases, the solvent rising to the top and being removed by means of line 20. The lower layer, comprising a concentrated emulsion comprising largely a latex with minor proportions of residual solvent is optionally passed by means of line 21 to centrifuge 22. Any serum comprising water and emulsifying agent removed thereby may be recycled by a line (not shown) to the emulsification zone of the process.

The concentrated mixture now contains a minor but substantial amount of residual solvent which is preferably removed by subjecting it to foam formation and collapse as hereinbefore described, in units 23, 24, and comprising the foam former 23, time tank 24 and foam condenser 25 and thereafter passed through a set of apparatus comprising the coalescer 26 and decanter 27. The purpose and results of each of these units are substantially identical with the corresponding pieces of apparatus described hereinbefore.

The bottom layer from the decanter 27 after removal of the top layer solvent comprises a latex containing a reduced but still substantial amount of solvent which is preferably removed at least in part by passage through a heater 28 to raise the temperature to about 180 F., the heated latex being then sent to a settler 29 for further removal of solvent which separates. The dilute latex is now sent by means of line 29A to a centrifuge 30 for still further removal of serum (water and emulsifying agent) which is recycled by means of line 31 to the serum tank 4.

The concentrated latex still contains traces of solvent which are removed by sending the concentrate by means of line 32 to flashing zone 33, the final product being a concentrated latex containing less than about 1% solvent based on the rubber and the product comprising about 65% colloidally dispersed rubber with 35% water containing about 0.35% by weight of potassium rosinate based on the water phase.

Example I Emulsions were prepared as described in reference to the figure comprising a cement of 10% polyisoprene and 90% mixed amylenes emulsified with an approximately equal amount of water containing 1.5% by weight based on water of potassium rosinate. The emulsions were fed to a reboiler designated at item 13 in the figure at desired temperatures and under a variety of pressures. It was found however, that variation in pressure did not make a material difference in the results obtained but that the residence time of the foam formed by heating in the reboiler comprised the important feature of the comparative experiments. The emulsions were fed to the reboiler at a rate of about 2 gallons per minute through a foam transfer line which at the exit of the reboiler had a volume of approximately 0.15 cubic foot. The residence time of the foam in this transfer line after formation was about 0.5 second prior to cooling for foam collapse. A parallel set of experiments were run in which a time tank was inserted at the exit side of the reboiler so as to provide a foam residence time in the order of 27 seconds. The table below indicates the advantage gained by the use of this longer residence time in reducing the amount of solvents retained within the latex subsequent to removal of the condensed and separated solvent layer. It will be seen according to Table I that substantially less solvent remained in the stripped latex when the longer residence time was employed.

Example 11 A similar set of experiments was performed utilizing as a feed to the reboiler a stripped latex containing about 5% by weight of residual solvent. The objective here was to remove a maximum amount of this residual solvent. In this set of experiments, the comparative residence times were 53 seconds and 1 second respectively, the results of which are given in Table II below.

TABLE II Residual Solvent, Foam Temp, 0 F. Percent u 53 Seconds 1 Second It will be noted according to the above table that the use of the relatively long residence time resulted in substan tially smaller amounts of residual solvents in the stripped latex than are obtained when only a short residence time is employed.

We claim as our invention:

1. The process for the preparation of a latex of an elastomeric polymer of a conjugated diene which comprises forming a cement of said polymer in a C hydrocarbon solvent, said cement having a polymer content between 5% and 30% by weight, emulsifying the cement with 0.5-2.5 volumes of water per volume of cement with 0.5% to 2.0% based on the water of an alkali metal soap of a monocarboxylic acid having at least 12 carbon atoms per molecule, heating the emulsion to a temperature sufficient to vaporize substantially all of the hydrocarbon solvent while maintaining the water in a liquid state, whereby a foam incorporating substantially all of the emulsion components is formed, holding the foam at about said temperature for 0.l2.5 minutes whereby the solvent distribution of the entire body of foam is equilibrated thereafter cooling the foam to a solvent liquifying temperature whereby the foam is collapsed, a major proportion of the solvent containing no more than a minor proportion of its original polymer content separates and is decanted, leaving a latex of the polymer containing no more than a minor proportion of solvent originally present in the cement.

2. A process according to claim 1 wherein the soap is potassium rosinate, the polymer is polyisoprene and the solvent is a mixture of amylenes.

References Cited by the Examiner UNITED STATES PATENTS 2,799,662 7/1957 Ernest et al. 26029.7 2,803,623 8/ 1957 Anderson 260-84.7 2,947,715 8/1960 Charlet et -al 260-297 3,003,930 10/1961 Pugh et al. 20246 MURRAY TILLMAN, Primary Examiner.

LOUISE P. QUAST, Examiner.

J. ZIEGLER, Assistant Examiner. 

1. THE PROCESS FOR THE PREPARATION OF A LATEX OF AN ELASTOMERIC POLYMER OF A CONJUGATED DIENE WHICH COMPRISES FORMING A CEMENT OF SAID POLYMER IN A C4-7 HYDROCARBON SOLVENT, SAID CEMENT HAVING A POLYMER CONTENT BETWEEN 5% AND 30% BY WEIGHT, EMULSIFYING THE CEMENT WITH 0.5-2.5 VOLUMES OF WATER PER VOLUME OF CEMENT WITH 0.5% TO 2.0% BASED ON THE WATER OF AN ALKALI METAL SOAP OF A MONOCARBOXYLIC ACID HAVING AT LEAST 12 CARBON ATOMS PER MOLECULE, HEATING THE EMULSION TO A TEMPERATURE SUFFICIENT TO VAPORIZE SUBSTANTIALLY ALL OF THE HYDROCARBON SOLVENT WHILE MAINTAINING THE WATER IN A LIQUID STATE, WHEREBY A FOAM INCORPORATING SUBSTANTIALLY ALL OF THE EMULSION COMPONENTS IS FORMED, HOLDING THE FORM AT ABOUT SAID TEMPERATURE FOR 0.1-2.5 MINUTES WHEREBY THE SOLVENT DISTRIBUTION OF THE ENTRIE BODY OF FOAM IS EQUILIBRATED THEREATER COOLING THE FOAM TO A SOLVENT LIQUIFYING TEMPERATURE WHEREBY THE FOAM IS COLLAPSED, A MAJOR PROPORTION OF THE SOLVENT CONTAINING NO MORE THAN A MINOR PROPORTION OF ITS ORIGINAL POLYMER CONTENT SEPARATES AND IS DECANTED, LEAVING A LATEX OF THE POLYMER CONTAINING NO MORE THAN A MINOR PROPORTION OF SOLVENT ORIGINALLY PRESENT IN THE CEMENT. 